160 SSC™ Variable Speed Drive (Series C) 0.37–4.0 kW (0.5–5 HP) FRN 7.03 FRN 7.04 FRN 7.05 FRN 7.06 User Manual Important User Information Solid-State equipment has operational characteristics differing from those of electromechanical equipment. “Safety Guidelines for the Application, Installation and Maintenance of Solid-State Controls” (Publication SGI-1.1) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation is prohibited. Throughout this manual we use notes to make you aware of safety considerations: ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss. Attention statements help you to: • identify a hazard • avoid a hazard • recognize the consequences Important: Identifies information that is especially important for successful application and understanding of the product. Shock Hazard labels located on or inside the drive indicate that dangerous voltage may be present. SSC is a trademark of Rockwell Automation, Inc. S-1 Series C Summary of Changes • New Horsepower Ratings • New Output Configuration Setting 4 kW (5 HP), 230V and 460V ratings have P47 - [Output Configure] has a new setting. been added to the Bulletin 160 family. When setting 10 is selected, the output Increased Transient Protection will be active when the Power Factor • Angle is above the P48 - [Output Threshold] Standard input voltage transient protection setting. has been increased to 6 kV and contained in the drive itself. The optional MOV • Additional Compensation Mode module is no longer required. P78 - [Compensation] has an additional Improved Ground Fault Protection mode that corrects for slow responding • systems which can cause current regulator The Bulletin 160 detects phase-to-phase oscillations. and phase-to-ground faults both at start-up and while running. • Software Current Trip P79 - [Software Current Trip] Reduced 2.2 kW (3 HP) Footprint provides an • adjustable software current trip with a one 2.2 kW (3 HP), 230V and 460V width has second time delay. been reduced by more than 45%. • Adjustable Stall Fault Time • One Piece, 1.5 kW (2 HP) 230V Single Phase Unit The time that the drive must be in a stall condition before causing a stall fault is The external capacitor module has been selectable via P80 - [Stall Fault Time]. integrated into the 1.5 kW (2 HP), 230V single phase unit. The overall width of the • PI Control unit is reduced, however, the height, Process control is now intergrated in the depth, and mounting hole pattern has drive through a PI regulator. Users of changed. Firmware Version FRN 7.05 and earlier P46 - [Input Mode] Improved Start/Stop Overlap Timing activate this feature with • setting 9. Users of Firmware Version FRN The STOP command can be removed up 7.06 can activate this feature with P46 - to 20 msec after a START command and [Input Mode] settings 0 through 7 and 9. the drive will still recognize the START PI control is adjusted through parameters command. This allows the drive to P81 - [PI Proportional Gain], P82 - [PI respond to a START command occurring Integrated Gain], P83 - [PI Process concurrently with or slightly after a STOP Reference], and P84 - [PI Dead Band]. command is removed. • Fault Auto Clear • Additional Fault History P17 P18 P19 - [Fault Buffer 0, 1 and 2] Over voltage, Under voltage, and Over , , and temperature faults are automatically have been added to record the last three cleared when the fault condition is faults for diagnostic purposes. removed. Analog Model with Preset Speed Capability • • RS-232 Serial Communication Analog Signal Follower models have an An RS-232 serial communication module additional input mode. With P46 - [Input Mode] using a DF1 protocol is now available. See setting 8, four preset speeds are 160-RS1 User Manual for additional available. information. • External Frequency Selection Ground Screw Location P46 - [Input Mode] • has an additional setting Grounding screws are now located on the (setting 7) which allows for the frequency power connection terminal blocks for source to be switched from the control easier wiring. terminal block (TB3) to the P58 - [Internal Frequency] setting. S-2 Series C Application/Installation Considerations Keep the following in mind if you are replacing a Bulletin 160 Series A or B drive with a Series C unit. Mounting Dimensions • Width has increased by 8 mm for all ratings through 1.5 kW (2 HP). Note: If proper spacing recommendations were followed for Series A and B drives, the increased width should not effect the panel layout because Series C drives of this rating do not require spacing between units. • Width has decreased by 50 mm for the 2.2 kW (3 HP) rating. • Depth has increased by 25 mm for all ratings through 2.2 kW (3 HP). Note: The drive utilizes the same DIN base and mounting hole pattern for all ratings through 2.2 kW (3 HP). External Braking • The internal brake transistor is not available on 0.37 kW (1/2 HP) and 0.55 kW (3/4 HP) units. If external braking is required, a 0.75 kW (1 HP) drive must be used. DeviceNet • DeviceNet modules (Catalog No.160-DN1) with Firmware Version FRN 2.0 or earlier are not compatible with the Bulletin 160 Series C drives. Series C drives must use DeviceNet modules (Catalog No. 160-DN2). The 160-DN2 module is also compatible with Series A and B drives with the exception of the Series A Preset Speed model with Firmware Version FRN 4.04. 24V DC Interface • Bulletin 160 Series C drives must use a Series B, or later, 24V DC Interface module. See Appendix B for catalog numbers. Terminal Block Wiring • The ground terminal is now located on the power terminal block. Refer to Figure 2.2 on page 2-3 to avoid incorrect wiring. Incorrect Motor Rotation • The output phasing of Series C drives is different than the output phasing of Series A and B drives. Replacing a Series A or B drive with a Series C drive using the same U, V and W (T1, T2 and T3) connections will reverse the motor rotation. To assure the same direction of rotation, switch any 2 of the 3 output wires connected to U, V or W (T1, T2 or T3) from the motor. Example: Original Wiring of Wiring of Replacement Series A or B Series C U/T1 V/T2 W/T3 U/T1 V/T2 W/T3 V/T2 V/T2 U/T1 W/T3 U/T1 W/T3 Motor Motor Table of Contents Getting Started Important Precautions . .1-1 Receiving Your New Drive . .1-2 Unpacking . .1-2 Inspecting . .1-2 Identifying Your Drive . .1-2 Catalog Number . .1-2 Nameplate . .1-3 Conventions Used In This Manual . .1-3 Standard Drive Features . .1-4 Optional Drive Features . .1-5 Installation and Wiring Storage and Operation Conditions . .2-1 CE Compliance . .2-1 Installation . .2-1 Clearances . .2-1 Debris Label . .2-1 Power Wiring . .2-2 Precautions . .2-2 Terminal Blocks . .2-2 Terminal Block Wiring . .2-3 Specifications . .2-3 Motor Branch Circuit Analysis . .2-4 Branch Circuit Protective Devices . .2-5 Input Power Conditioning . .2-6 Motor Cable Types . .2-6 Long Motor Cable Effects . .2-7 Control Wiring . .2-9 Requirements . .2-9 Specifications . .2-9 Important Precautions . .2-9 Control Wiring Considerations . .2-10 Control Methods and Selection Guide . .2-11 Configurable Relay Output Contacts (P47 Settings) . .2-18 Frequency Source Wiring . .2-18 Analog Signal Follower Model . .2-18 Preset Speed Model . .2-20 Analog and Preset Models . .2-20 What To Do Next . .2-20 ii Program Keypad Module Features . 3-1 Display Mode . 3-1 Program Mode . 3-1 Key Functions . ..